An experimental investigation of flow boiling in an asymmetrically heated rectangular microchannel

By using unique experimental techniques and carefully constructed experimental apparatus, the characteristics of flow boiling of water in microscale were investigated using a single horizontal rectangular microchannel. A polydimethylsiloxane rectangular microchannel (D_h = 103.5 and 133 μm) was fabricated by using the replica molding technique, a kind of soft lithography. A piecewise serpentine platinum microheater array on a Pyrex substrate was fabricated with the surface micromachining MEMS technique. Real time flow visualization of the phase change phenomena inside the microchannel was performed using a high speed CCD camera with microscope. The experimental local boiling heat transfer coefficients were studied, and single bubble inception, growth, and departure, as well as elongated bubble behavior were analyzed to elucidate the microscale heat transfer mechanisms. Tests were performed for mass fluxes of 77.5, 154.9, and 309.8 kg/m² s and heat fluxes of 180–500 kW/m². The effects of mass flux, heat flux, and vapor qualities on flow boiling heat transfer in a microchannel were studied.     

Convective boiling of halocarbon refrigerants flowing in a horizontal copper tube – an experimental study

An experimental study of convective boiling of refrigerants R-22, R-134a and R-404A in a 12.7 mm internal diameter, 2 m long, horizontal copper tube has been performed. Experiments involved a relatively wide range of operational conditions. Experiments were performed at the evaporating temperatures of 8°C and 15°C. Quality, mass velocity and heat flux varied in the following ranges: 5% to saturated vapor, 50–500 kg/(s m²); and 5–20 kW/m². Effects of these physical parameters over the heat transfer coefficient have been investigated. High quality experiments were also performed up to the point of the tube surface dryout, a mechanism which was investigated from the qualitative point of view. Two heat transfer coefficient correlations from the literature have been evaluated through comparisons with experimental data. Deviations varied in the range from −25% to 42%.     

Heat transfer correlation for boiling flows in small rectangular horizontal channels with low aspect ratios

In the present experimental study, a correlation is proposed to represent the heat transfer coefficients of the boiling flows through horizontal rectangular channels with low aspect ratios. The gap between the upper and the lower plates of each channel ranges from 0.4 to 2 mm while the channel width being fixed to 20 mm. Refrigerant 113 was used as the test fluid. The mass flux ranges from 50 to 200 kg/m² s and the channel walls were uniformly heated up to 15 kW/m². The quality range covers from 0.15 to 0.75 and the flow pattern appeared to be annular. The modified Lockhart–Martinelli correlation for the frictional pressure drop was confirmed to be within an accuracy of ±20%. The heat transfer coefficients increase with the mass flux and the local quality; however the effect of the heat flux appears to be minor. At the low mass flux condition, which is more likely to be with the smaller gap size, the heat transfer rate is primarily controlled by the liquid film thickness. A modified form of the enhancement factor F for the heat transfer coefficient in the range of Re_LF200 well correlates the experimental data within the deviation of ±20%. The Kandlikar's flow boiling correlation covers the higher mass flux range (Re_LF>200) with 10.7% mean deviation.     

Experimental research on transient critical heat flux in vertical tube under oscillatory flow condition

The transient critical heat flux (CHF) experiments with forced sinusoidal inlet flow oscillation (oscillation period in 1–11 s, normalized amplitude of inlet flow oscillation in 0–3.0) were conducted in a vertical tube under low pressure condition. To analyze the triggering mechanism and aftermath of periodic dryout, the wall temperature fluctuation characteristics at the onset of periodic dryout and during post-periodic dryout were investigated. Under inlet flow oscillation condition, periodic dryout would be triggered at the wave trough of liquid film oscillation as wall heat flux far below the stable-flow CHF. The transient periodic dryout would give rise to temperature fluctuations on the tube wall, the amplitude of which increased with oscillation period and heat flux. The large wall temperature fluctuation during long-playing periodic dryout could significantly pre-trigger continuous dryout. The changing trends of the periodic dryout heat flux show a reasonable agreement with Okawa’s theoretical model, in which the liquid film oscillation was supposed be weakened by the axial mixing of liquid film. Moreover, the droplet entrainment at the oscillatory interface also has noticeable influence on the oscillation characteristics of liquid film. Based on the analysis of parameter effects on periodic dryout, a semi-empirical correlation was proposed to predict the periodic dryout heat flux under inlet flow oscillation condition.     

Two-phase heat transfer characteristics for R-22/R-407C in a 6.5-mm smooth tube

Two-phase friction and heat transfer characteristics for R-22/R-407C inside a 6.5-mm smooth tube are reported in this study. The heat transfer results for G=100 and 400 kg/m² s were reported in the present study, and the adiabatic frictional pressure drop was recorded in the range of 100 to 700 kg/m² s. It is found that the development of flow pattern for R-407C falls behind R-22. This may explain the lower pressure drops for R-407C. The major heat transfer mechanism at low mass flux is nucleate boiling, and virtually becomes the convective evaporation as mass flux increase to G=400 krg/m² s, Meanwhile, the reduction of heat transfer coefficients for R-407C mixtures are especially profound at low mass flux, and the reduction of heat transfer coefficient decreases with the increase of mass flux.     

Thermal characteristics of a high heat flux micro-evaporator

Our purpose is to design a high heat flux micro-evaporator that can remove more than 100 W/cm². For this purpose a thin liquid film is evaporized. The liquid film is stabilized in micro-channels by capillary forces. The micro-channels are fabricated by chemical etching on silicon to reduce thermal resistance. For the experiments, the channel plate is heated by an ITO thin film heater deposited on the opposite side of the channel plate. Influence of heat flux, coolant flow rate, and inlet temperature on the temperature of the heater element are investigated. Water is used as working fluid. A maximal heat flux of 125 W/cm² could be achieved for water inlet temperature of 90 °C and flow rate of 1.0 mL/min. The temperature of the heater element is kept constant at about 120 °C with fluctuations within 8 °C. The measured pressure drop is less than 1000 Pa.     

Dryout in serpentine evaporators

Waterside on-load corrosion failures in power station evaporators have resulted from dryout along the upper surfaces of the tubes in serpentine arrangements.

It is shown that this type of dryout can occur at intermediate qualities over a wide range of flow rates and pressures for heat fluxes much less than in vertical tubes.

A type of flow which is here called “surge flow” has been identified as being particularly likely to lead to dryout, because the top surfaces are wetted only intermittently by waves or plugs of frothy liquid.

A method is being developed for assessing the likelihood of dryout under surge flow conditions. It correctly predicts the dryout boundaries in a pressurized steam/water facility.     

Recent achievements in the thermal hydraulics of high heat flux components in fusion reactors

Some components of fusion thermonuclear reactors, such as divertors, plasma limiters, or first-wall armor, are believed to be subjected to operating conditions characterized by extremely high thermal loads. It is therefore necessary to remove from the surface of these components very high heat fluxes, ranging from 2 to 60 MW/m². Water subcooled flow boiling, under conditions of high mass flux, high liquid subcooling, and small to intermediate channel diameter, can accomodate these very high heat fluxes. Further enhancement of the upper limit of cooling, the critical heat flux (CHF), can be obtained by making use of turbulence promoters such as twisted tapes and coiled wires even if coupled with a relevant increase in pressure drop. An overview is presented of recent achievements obtained in water subcooled flow boiling CHF under operating conditions of interest to the thermal hydraulic design of fusion reactors. Observed basic parametric trends—CHF as a function of mass flux, pressure, subcooling, and channel geometry—are outlined, together with findings on the use of CHF enhancement techniques. From experiments it was seen that water subcooled flow boiling allows CHF conditions as high as 228 MW/m² to be achieved under extreme geometric and thermal hydraulic conditions. On the other hand, design and engineering boundary conditions limit variation in these conditions, and a suitable compromise has not yet been reached. Predictive tools are presented for the evaluation of subcooled flow boiling CHF both in straight tubes and with twisted tapes, and are assessed with reference to recent available experimental data.

Although several indications for practical applications can be found in recent achievements, a full understanding of the basic mechanisms of heat transfer and CHF in subcooled flow boiling has not yet been achieved. Future research to overcome the present lack of knowledge in this field is suggested.     

Characteristics of the critical heat flux for downward flow in a vertical tube at low flow rate and low pressure conditions

The characteristics of the critical heat flux (CHF) for downward flow were studied experimentally with an Inconel 600 circular tube test section in a water test loop at low-flow rate (0 200 kg/m²s) and low-pressure (0.1 0.7 MPa) conditions. The attention was given to the effects of upstream conditions—upper plenum and inlet throttling. Two totally different kinds of CHF behaviors were observed. It seems appropriate to interpret them as flooding-type CHF and dryout in annular flow. The CHF in downward flow may vary from extremely unstable flow CHF as low as near the flooding CHF value to stable flow CHF as high as that of upflow, depending on the upstream conditions of the test section. The CHF correlation by Mishima and that by Weber were proposed for the presentation of the lower and upper limits of the CHF for downward flow in a vertical tube at low-flow rate and low-pressure conditions.     

Experimental study of CHF in vertical and horizontal tubes cooled by freon-12

The influence of test section orientation and diameter on flow boiling crisis occurring in tubes has been studied experimentally using Freon-12 as a coolant. At low mass flux the critical heat flux (CHF) was lower in horizontal flow than in vertical. As either the liquid or vapour velocity, or both, were increased the vertical and horizontal CHF results converged. Above a mass flux of 4Mg · m⁻² · s⁻¹ the results were essentially identical.

The effect of tube diameter on boiling crisis in general depends crucially on the parameters which are maintained constant when the comparison is made.     

Condensation from steam—air mixtures in a horizontal annular flow channel

Experiments were performed on the condensation of steam from steam-air mixtures in annular flow at a cooled inner tube. The range of investigation was varied for laminar and turbulent flow for 1.5 × 10³ Re 1.3 × 10⁴ and inlet concentrations 0.59 p_steam/p_total 0.95. The measurements, performed at an open test loop at p_total ≈ 0.96 bar, allowed local heat and mass transfer coefficients to be evaluated for various inlet lengths in the 2 m long annulus. The steam concentration was measured locally inside the annulus with a newly developed dew-point probe. The heat flux was measured locally using the temperature gradient in the cooled inner tube.

Near the inlet region the experiments showed a slightly higher heat flux at the bottom of the tube compared to the top, although it is expected to be smaller there owing to a thicker liquid film. Far downstream from the inlet region the heat transfer at the top was higher than at the bottom. The reasons for these effects are discussed, yielding a better understanding of the thermal and fluid processes involved in condensation from vapor-gas mixtures. The measured data allow the development of correlations for predicting the local Nusselt and Sherwood numbers in a horizontal annular-flow chanbel.     

Explosive boiling of water in parallel micro-channels

The objective of this study is to visualize the flow pattern and to measure heat transfer coefficient during explosive boiling of water in parallel triangular micro-channels. Tests were performed in the range of inlet Reynolds number 25–60, mass flux 95–340 kg/m²s, and heat flux 80–330 kW/m².The flow visualization showed that the behavior of long vapor bubbles, occurring in a micro-channel at low Reynolds numbers, was not similar to annular flow with interposed intermitted slugs of liquid between two long vapor trains. This process may be regarded as explosive boiling with periodic wetting and dryout.In the presence of two-phase liquid–vapor flow in the micro-channel, there are pressure drop oscillations, which increase with increasing vapor quality.This study shows strong dependence of the heat transfer coefficient on the vapor quality. The time when liquid wets the heated surface decreases with increasing heat flux. Dryout occurs immediately after venting of the elongated bubble.     

Heat transfer in bubble layers at elevated pressures

Heat transfer with steam condensation under moderate pressure on the surface of a horizontal tube immersed in a bubbling layer was experimentally investigated. A copper test section 16 mm in outer diameter and 400 mm in length was placed in a bubbling column 455 mm in diameter. Experiments were made under pressures of 0.14–0.8 MPa, with void fraction 0.04–0.23, vapor superficial velocities 0.05–0.42 m/s, liquid-wall temperature differences 47–105 K, and heat flux densities 0.12–0.8 MW/m². The heat transfer process in the bubbling layer is shown to be of a high intensity: with moderate values of steam content, heat transfer coefficients reach 12–14 kW/(m² · K). Data obtained showed that the known correlations do not consider the influence of pressure on heat transfer. For the first time, data on radial steam content distribution under pressures higher than atmospheric were obtained by an electroprobe method. A table of experimental data is presented.     

The analysis of a mechanism of liquid replenishment and draining in horizontal two-phase flow

There is a regime of two-phase flow in which large waves or surges pass rapidly along a horizontal tube accompanied by splashing, wave-breaking and entrainment with the result that water is thrown to the upper surface of the tube. Between surges the film on the top surface is depleted by draining under gravity and by evaporation if the tube is heated. If the interval between surges is sufficiently long a dry patch may begin to form. In this paper, theory is given for the calculation of the film thickness left behind on the top surface and for the calculation of the time to dryout. The theory includes both the effect of the boundary layer developement during replenishment of the film and also the effect of the axial deceleration of the film at the point where the liquid replenishment ceases. Finally, the predicted variation of film thickness is compared with experimental film thickness traces obtained in this type of horizontal two-phase flow. The agreement is found to be very satisfactory. This analysis is of interest in connection with the prevention of permanent and intermittent dryout at low qualities in nuclear power station evaporators.     

Microscale heat transfer in an evaporating moving extended meniscus

The evaporative heat flux distribution in the leading edge region of a moving evaporating thin liquid film of pentane on quartz was obtained by analyzing the measured thickness profile for thicknesses, δ < 2 μm. The profiles in a constrained vapor bubble were obtained using image analyzing interferometry. Although the evaporating meniscus appeared to be benign (i.e., without additional observed motion beyond creeping), high heat fluxes were obtained. Significantly higher heat fluxes are possible. The interfacial slope, curvature, interfacial shear stress, and liquid pressure profiles were also obtained. Results obtained using a continuum model were consistent with those obtained using a control volume model. The measured pressure field profile of the isothermal extended meniscus agreed with the constant pressure field predicted by the augmented Young–Laplace model. For the non-isothermal case, measured thickness gradients lead to disjoining pressure and curvature gradients for fluid flow and evaporation. The experimental results demonstrate that disjoining pressure at the contact line controls fluid flow within an evaporating completely wetting thin curved film and is, therefore, a useful boundary condition. However, in small interfacial systems, non-idealities can have a dramatic effect.     

Two-phase flow of refrigerants in 85 μm-wide multi-microchannels: Part II – Heat transfer with 35 local heaters

This article is the second part of a study on flow boiling of R236fa and R245fa. This part presents the heat transfer coefficients obtained in a 12.7 mm silicon evaporator composed of 135 microchannels with 85 μm wide and 560 μm high channels separated by 46 μm wide fins. There were 35 local heaters and temperature measurements arranged in a 5 × 7 array. The heat transfer results were uniform in the lateral direction to the flow (attributable to the inlet restriction) and a function of the heat flux, vapor quality and mass flux. The steady-state standard deviation of the local base temperature was less than 0.2 °C, inferring that the boiling process was very stable. For wall heat fluxes over 45 kW/m², the heat transfer coefficient curves were V-shaped, decreasing for intermittent flow regimes and increasing for annular flow. The three-zone model of Thome et al. (2004) was the best heat transfer prediction method when setting the dryout thickness equal to the channel roughness.     

Measurements and high-speed visualizations of flow boiling of a dielectric fluid in a silicon microchannel heat sink

Experiments were conducted to investigate flow boiling heat transfer to a dielectric fluid in a silicon chip-integrated microchannel heat sink. Twenty-four microchannels, each 389 μm × 389 μm in cross-section, were fabricated into the 12.7 mm × 12.7 mm silicon substrate. High-speed visualizations (at 12,500 frames per second) were performed simultaneously with heat transfer and pressure drop measurements to investigate the physics of flow boiling in parallel microchannel arrays. At low heat fluxes, bubbly flow is dominant, with the bubbles coalescing to form vapor slugs as the heat flux is increased. At high heat fluxes, the flow regimes in the downstream portion of the microchannels are characteristic of alternating wispy-annular flow and churn flow, while flow reversal is observed in the upstream region near the microchannel inlet. Local heat transfer measurements, obtained at three flow rates ranging from 35 to 60 ml/min, show that at lower heat fluxes, the heat transfer coefficient increases with increasing heat flux. The heat transfer coefficient in fully developed boiling is seen to be independent of flow rate in this range. At higher heat fluxes (exceeding 542, 673, 730 kW/m², respectively, for flow rates of 35, 47 and 60 ml/min), this trend is reversed, and the heat transfer coefficient decreases with further increases in heat flux due to partial dryout in some of the microchannels. Heat fluxes at which fully developed boiling is achieved depend on the flow rate. The pressure drop in fully developed boiling increases with increasing heat flux and is independent of flow rate for the test conditions considered in this work.     

A mechanistic critical heat flux model for subcooled flow boiling based on local bulk flow conditions

The critical heat flux (CHF) mechanisms for subcooled flow boiling are reviewed. Based on experimental observations reported by previous investigators, the authors have developed a new mechanistic CHF model for vertical subcooled flow at high pressure and high mass velocity. This model is based on the dryout of a thin liquid layer (sublayer) beneath an intermittent vapor blanket due to a Helmholtz instability at the sublayer-vapor interface. The parametric trends of CHF have been explored qualitatively and quantitatively with respect to variations in pressure, mass velocity, subcooling and tube diameter. Comparisons of the model predictions with experimental data for water show good agreement in the simulation of subcooled flow conditions of pressurized water reactors (PWRs).     

Combustion of textile residues in a packed bed

Textile is one of the main components in the municipal waste which is to be diverted from landfill for material and energy recovery. As an initial investigation for energy recovery from textile residues, the combustion of cotton fabrics with a minor fraction of polyester was investigated in a packed bed combustor for air flow rates ranging from 117 to 1638 kg/m² h (0.027–0.371 m/s). Tests were also carried out in order to evaluate the co-combustion of textile residues with two segregated waste materials: waste wood and cardboard.

Textile residues showed different combustion characteristics when compared to typical waste materials at low air flow rates below 819 kg/m² h (0.186 m/s). The ignition front propagated fast along the air channels randomly formed between packed textile particles while leaving a large amount of unignited material above. This resulted in irregular behaviour of the temperature profile, ignition rate and the percentage of weight loss in the ignition propagation stage. A slow smouldering burn-out stage followed the ignition propagation stage. At air flow rates of 1200–1600 kg/m² h (0.272–0.363 m/s), the bed had a maximum burning rate of about 240 kg/m² h consuming most of the combustibles in the ignition propagation stage. More uniform combustion with an increased burning rate was achieved when textile residues were co-burned with cardboard that had a similar bulk density.     

An investigation of a model of the flow pattern transition mechanism in relation to the identification of annular flow of R134a in a vertical tube using various void fraction models and flow regime maps

In the present study, new experimental data are presented for literature on the prediction of film thickness and identification of flow regime during the co-current downward condensation in a vertical smooth copper tube having an inner diameter of 8.1 mm and a length of 500 mm. R134a and water are used as working fluids in the tube side and annular side of a double tube heat exchanger, respectively. Condensation experiments are done at mass fluxes of 300 and 515 kg m^?2 s^?1. The condensing temperatures are between 40 and 50 °C; heat fluxes are between 12.65 and 66.61 kW m^?2. The average experimental heat transfer coefficient of the refrigerant HFC-134a is calculated by applying an energy balance based on the energy transferred from the test section. A mathematical model by Barnea et al. based on the momentum balance of liquid and vapor phases is used to determine the condensation film thickness of R134a. The comparative film thickness values are determined indirectly using relevant measured data together with various void fraction models and correlations reported in the open literature. The effects of heat flux, mass flux, and condensation temperature on the film thickness and condensation heat transfer coefficient are also discussed for the laminar and turbulent flow conditions. There is a good agreement between the film thickness results obtained from the theoretical model and those obtained from six of 35 void fraction models in the high mass flux region of R134a. In spite of their different valid conditions, six well-known flow regime maps from the literature are found to be predictive for the annular flow conditions in the test tube in spite of their different operating conditions.